Front

FRONT BRAKE (for 3GR-FSE)

Components:

REMOVAL

HINT:
^ Use the same procedures for the RH side and LH side.
^ The procedures listed below are for the LH side.

1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID

NOTICE: If brake fluid leaks onto any painted surface, wash or otherwise remove it completely

3. REMOVE FRONT DISC BRAKE CYLINDER ASSEMBLY
a. Remove the union bolt and gasket from the disc brake cylinder assembly, then disconnect the flexible hose.

b. Remove the 2 bolts and disc brake cylinder assembly.

DISASSEMBLY
1. REMOVE FRONT DISC BRAKE PAD KIT
a. Remove the 2 brake pads with anti-squeal shims.

2. REMOVE ANTI-SQUEAL SHIM KIT FRONT
a. Remove the 2 anti-squeal shims and the 2 pad wear indicator plates from each pad.

3. REMOVE FRONT DISC BRAKE PAD SUPPORT NO.1 PLATE
4. REMOVE FRONT DISC BRAKE PAD SUPPORT NO.2 PLATE
5. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Remove the cylinder slide pin from the cylinder mounting LH.

6. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH
a. Using a screwdriver, remove the cylinder slide bush from the cylinder slide pin.

HINT: Tape the screwdriver tip before use.

7. REMOVE FRONT DISC BRAKE CYLINDER NO.2 SLIDE PIN
a. Remove the cylinder slide pin No.2 from the cylinder mounting LH.

8. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Remove the 2 bolts and cylinder mounting LH.
b. Remove the 2 caliper plates No.1 from the cylinder mounting LH.

9. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
a. Secure the cylinder mounting LH in a vise.
b. Using a screwdriver and a plastic hammer, remove the 2 bush dust boots.

10. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the set ring or cylinder boot.

NOTICE: Do not damage the inner cylinder or cylinder groove.

HINT: Tape the screwdriver tip before use.

11. REMOVE FRONT DISC BRAKE PISTON
a. Place a shop rag or piece of cloth between the piston and the disc brake cylinder assembly.
b. Use compressed air to remove the piston from the disc brake cylinder assembly.

CAUTION: Do not place your fingers in front of the piston when using compressed air.

NOTICE: Do not spatter the brake fluid.

12. REMOVE PISTON SEAL
a. Using a screwdriver, remove the piston seal from the disc brake cylinder assembly

NOTICE: Do not damage the inner cylinder or cylinder groove.

HINT: Tape the screwdriver tip before use.

13. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
14. REMOVE FRONT DISC BRAKE BLEEDER PLUG

15. REMOVE FRONT DISC
a. Put matchmarks on the disc and the axle hub.
b. Remove the front disc.

REASSEMBLY
1. INSTALL FRONT DISC
a. Align the matchmarks, install the front disc.

HINT: When replacing the disc with a new one, select the installation position where the front disc has the minimum runout.

2. TEMPORARILY TIGHTEN BLEEDER PLUG CAP
3. INSTALL FRONT DISC BRAKE BLEEDER PLUG
4. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to a new piston seal.
b. Install the piston seal to the disc brake cylinder assembly.

5. INSTALL FRONT DISC BRAKE PISTON
a. Apply lithium soap base glycol grease to the piston and a new cylinder boot.
b. Install the cylinder boot to the piston.
c. Install the piston to the disc brake cylinder assembly.

NOTICE: Do not install the piston forcibly in the cylinder assembly.

6. INSTALL CYLINDER BOOT
a. Install the cylinder boot to the disc brake cylinder assembly.

NOTICE: Install the boot securely to the grooves of the cylinder and piston.

b. Using a screwdriver, install a new set ring.

NOTICE:
^ Install the set ring securely to the grooves of the cylinder boot.
^ Do not damage the cylinder boot.

HINT: Tape the screwdriver tip before use.

7. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
a. Secure the cylinder mounting LH in a vise.
b. Apply lithium soap base glycol grease to the seal surface of 2 new bush dust boots.
c. Using a socket wrench (21 mm) and a hammer, install the 2 bush dust boots.

8. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Install 2 new caliper plate No.1 to the cylinder mounting LH.
b. Install the cylinder mounting LH with the 2 bolts.
Torque: 78 Nm (799 kgf-cm, 58 ft. lbs.)

9. INSTALL FRONT DISC BRAKE CYLINDER NO.2 SLIDE PIN
a. Apply lithium soap base glycol grease to the sliding part and the seal surface of the cylinder slide pin No.2.
b. Install the cylinder slide pin No.2 to the cylinder mounting LH.

NOTICE: Insert the slide pin No.2 into the cylinder mounting LH lower side.

10. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Apply lithium soap base glycol grease to the sliding part and the seal surface of the cylinder slide pin.
b. Install the cylinder slide pin to the cylinder mounting LH.

NOTICE: Insert the slide pin into the cylinder mounting LH upper side.

11. INSTALL FRONT DISC BRAKE PAD SUPPORT NO.2 PLATE
12. INSTALL FRONT DISC BRAKE PAD SUPPORT NO.1 PLATE

13. INSTALL ANTI- SQUEAL SHIM KIT FRONT
a. Apply disc brake grease to the 2 ant-squeal shims No.1 and install them to each pad.

NOTICE: When replacing worn pads, the anti-squeal shims must be replaced together with the pads.

b. Install the 2 anti-squeal shims No.2 to each pad.

NOTICE: Install them with attention to the direction of the grooves on the disc brake pads.

HINT:
^ The parts of the same part number are used for the inner and outer pads.
^ The RH side pad is symmetrical to the LH side pad.
^ Correctly install the brake pads by checking the mark, R or L, engraved on the back of the pads.

c. Install the 2 pad wear indicator plates to each pad.

NOTICE: Install the pad wear indicator plates in the correct positions and directions.

14. INSTALL FRONT DISC BRAKE PAD KIT
a. Install the 2 pads with pad wear indicator plates to the cylinder mounting LH.

NOTICE: Install them with attention to the direction of the grooves on the disc brake pads.

INSTALLATION

1. INSTALL DISC BRAKE CYLINDER ASSEMBLY LH
a. Install the disc brake cylinder assembly with the 2 bolts.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)

b. Connect the flexible hose with the union bolt and a new gasket.
Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.)

NOTICE: Install the flexible hose lock securely in the lock hole in the disc brake cylinder.

2. ADD RESERVOIR WITH BRAKE FLUID
3. BLEED BRAKE LINE
4. INSPECT FLUID BRAKE FLUID LEVEL IN RESERVOIR
5. INSPECT BRAKE FLUID LEAKAGE
6. CHECK AND CLEAR DTC
7. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)